Apparatus for converting a tubular web to a flat web



J. GOLDMAN May 12, 1964 APPARATUS FOR CONVERTING A TUBULAR WEB TO A FLATWEB 3 Sheets-Sheet 1 Filed Sept. 1, 1959 INVENTOR. JosHt/A GGLDMAN BY MQMM ATTORNEY J. GOLDMAN May 12, 1964 APPARATUS FOR CONVERTING A TUBULARWEB TO A FLAT WEB 3 Sheets-Sheet 2 Filed Sept. 1, 1959 ATTORNEY May 12,1964 J. GOLDMAN 3,132,936

APPARATUS FOR CONVERTING A TUBULAR WEB TO A FLAT WEB Filed Sept. 1, 19593 Sheets-Sheet 3 iiiiiiiiii'g r INVENTOR. JosHu/l G04 OMAN ATTORNEYUnited States Patent 3,132,986 A?PARATUS EEG (ZQNVEI-ETENG A TUBULAR WEBTU A FLAT WEB Joshua Goldman, Hadlyrne Laboratories, Hadiyme, Conn.Filed Sept. 1, 195 9, Ser. No. 837,485 2 Claims. ((31.156-427) Theinvention relates to textiles, and more particularly to a method and amachine for making non-woven fabric products.

According to one specific form of the invention, a roll of paper tapehaving suitable adhesive is fed into a machine which curls the paper webtransversely into tubular form. The tubular web passes over a mandrelaround which rotates a set of creels, in opposite directions. Thesecreels wrap, helically around the tubular tape, as it progresses, layersof flexible strands which adhere to the tape. At the exit end of themandrel a cutter slits the sleeve of helically wound strands, at thelongitudinal edges of the tubular tape, and the composite product passesover a transformer roll of suitable wavy contour to facilitate change ofthe composite product from circular transverse shape to straighttransverse shape, whence the product is drawn by puller rolls and woundup onto storage rolls.

In said specific form of the invention, the creels have a series ofaxially-extending reeds having guides for feeding the strands to thetape. The reeds comprise rods inside of helical coils, and the spacesbetween convolutions constitute the guides for the strands. Suitableadjustment is provided to insure laying down the strands in smoothlayers and for varying the width of the layers.

It is an object of the invention to provide a method of and means forproducing a web of paper, woven cloth, plastic, etc., in sheet or tapeform, reinforced with crossed strands composed of suitable fibers orfilaments.

Such reinforced tape has extensive commercial use, for example, forbinding packages or shipping containers. In sheet form, it may be alsoused in tire carcasses, plastic body structures, plane fuselages, boatcoverings, hydraulic pipe and many other places requiring reinforcedflexible sheets.

Another object of the invention is to provide a method and means forproducing this reinforced tape continuously and in a shnple andinexpensive manner.

The invention consists generally in steps and means whereby theabove-named objects, together with others which will appear hereinafter,are attainable, and the invention will be more readily understood byreference to the accompanying drawings which illustrate the presentlypreferred form.

In the said drawings:

FiG. l is a semi-diagrammatic side elevation of the entrance end of themachine according to the invention. The work moves through the machinein the direction of the arrow B.

FIG. 1A is a continuation view of the exit end of the machine of FIG. 1,the matching lines being indicated by AA.

FIG. 2 is a semi-diagrammatic plan view of the machine.

FIG. 3 is a vertical section, taken on the line 3-3' of FIG. 2, showingrelationship of forming ring, mandrel, slitter, paper strip andnon-woven fabric.

FIG. 4 is a transverse vertical section, taken on the line 44 of FIG. 3,illustrating the support for the mandrel.

FIG. 5 is a transverse vertical section, taken on the line 5-5 of FIG.3, illustrating the forming ring.

FIG. 6 is a detail of the drive for driving the creels in oppositedirections.

FIG. 7 is a transverse section, taken on the line 7-7 3,l32,98fiPatented -May 12, 1-964 of FIG. 1, illustrating the construction of thecreels, showing bobbins, reeds, tension bars, etc.

FIG. 8 is a section, on the line 88 of FIG. 7, illustrating constructionof a creel and means for adjustingthe reed to fix the position of thethreads and width of a lay of threads.

FIG. 9 illustrates adjustment of the reeds for one width of lay.

FIG. 10 is a view corresponding to FIG. 9 showing reed adjustment for adifferent width of lay.

FIG. 11 is a fragmentary side elevation,.partly in section of aremovable mounting for a bobbin.

FIG. 12 is a section on the line Iii-12 of FIG. 11.

In the following description and in the claims various details will beidentified by specific names for convenience, but they are intended tobe as plication as the art Will'perim't.

In the drawings (where like reference characters denote like parts inthe several figures) and in this description, certain specificdisclosure of the invention is made for purposes of explanation, but itwill be understood the details may be modified in various respectswithout departure from the broader aspects of the invention.

Referring now to the drawings, and more particularly to FIGS. 1, 1A and2,,the travel of the Work through the machine will first be described.It will be understood that the several rolls, creels and other operatingparts are supported and journaled on a suitable frame work 39 which maybe of any necessary or desired form.

The pre-formed backing web it may be of any woven or felted cloth or ofpaper, and the continuous strands 3'1, 32 wrapped around the web may becontinuous filaments, single or multiple; or yarns of staple fibers. Thematerials from which the felted or woven cloth, paper and strands aremade, may be any of the common materials used for these purposes, suchas natural or artificial fibers: cotton, wool, linen, etc.; plastic,such as nylon; glass, metal, etc. In the specific form described'forpurposes of illustration, the web 10 is apaper tape.

The fiat tape 1 which is subsequently reinforced. by the strands,unrolls from a supply roll 11 and is fed through guiderrolls 12 thenceover a first transformer roll 12' to a tube-forming ring 13 (FIG. 5)which, as the tape 10 advances, shapes it into a tube with the'edges '14in close proximity on the under side of the thus formed tube. The tube'10 advances to surround a hollow cylindrical mandrel 15 with theadjacent edgesjld separating enough to pass the thin mandrel supports16.

Means for the continuous advance of the tape 10 is provided by apower-driven set of puller rolls 17 at the opposite or exit end of theapparatus, as shown in'FIG. 1A, which rolls grip by pinching the tape Itbetween their cylindrical surfaces.

The tube 10 continues to advance along the mandrel 15 through therotating creels 118 and 19 as shown in FIGS. 1, 2, 7 and 8, which creelswind layers of strands successively about the tube in oppositedirections as hereinafter described. The layers of strands are denotedgenerally by 20.

During the winding or laying on operations, the tube 10 with thewound-on strands 26 may be spnayed or otherwise treated by devices (notshown) with suitable adhesive such as a thermosetting resin or the liketo bond the strands 20 to the tape. If one side of the tape (i.e. theside which becomes the convex surface of the tube) is precoated with a.film of adhesive, as for example, pressure sensitive adhesive orthe'rmosetting adhesive, it may not be necessary to use the spray orlike treatment. To assist the setting of the adhesive, heat may besupplied to the mandrel 15 by any suitable means.

As the tube 10, which is now wound with layers of diagonal,substantially transverse strands 2t continues to generic in theirapadvance, the strands, which now are an integral part of the tube, areslit at the bottom of the tube between edges 14 by a slitter 21, inorder that the composite tube may subsequently be flattened out into astrip or narrow sheet 10, 20.

From the point of slitting, the tube 10, 2t begins to open up tosubsequently flatten out, as shown in FIG. 2, as the tape passes over asecond or transformer roll 22 and thence to the flat shape finallyproduced by the straight cylinders comprising the puller rolls 17.Leaving the puller rolls '17 the composite tape 10, 20 is coiled on abuncher roll 23. The rolls of finished tape are now in convenient formfor handlingeither for storage or use.

The forming ring 13, shown especially in FIGS. 3 and 5, shapes the tapeinto a tube and guides it for subsequent treatment on the mandrel '15.The ring has a rounded edge 24 to ease entry of the tape and to let itslide easily along while changing from fiat to tubular form.

The mandrel (FIG. 3) is located immediately following the shaping ring13 and supports the tube '10 during the winding operation. The outsidecylindrical surface of the mandrel is smooth to permit the easy passageof the tube 10 along its length. The mandrel 15 is hollow and has itsends closed with suitable fittings to allow pipe connections 26, 27 tobe attached to enable circulation of a heated fluid to assist in curingthe adhesive used to secure the strands 2.0 to the surface of the tube10. Other heating means maybe employed such as electric heating coils(not shown) placed inside of the mandrel. The mandrel 15 is secured ateach end by narrow supports 16 and 16' to permit the edges 14 of theshaped tube to pass.

The slitter 21 comprises a conventional rotatable disc having itsperiphery ground to a sharp cutting edge. It is moimted on a shaft anddriven in any desired way such as a separate electric motor 28. Theslitter 21 is located at the exit end of the mandrel 15, the mandrelhaving a suitable clearance recess 29 at the bottom. The slitter cutsthe strands 20 at a point where the adhesive has sufiiciently set tofirmly adhere the layers of strands 20 to the tape 16 without danger ofseparation or unravelling.

The strand winding mechanism, or creels 18, 19, are designed to wind aplurality of parallel strands 20 in layers around the tube formed by thetape 16. The first layer 31 is wound in one direction (counterclockwise,FIG. 7) and the second layer 32 in the opposite direction, so that thestrands in the second layer substantially cross those in the firstlayer. Each subsequent layer, if more than two creels are used, is woundin the opposite direc tion to the layer immediately under it.

Since the creels 18, 19 are of similar construction, it is onlynecessary to describe one in detail. Creel 13, as shown indetail inFIGS. 7 and 8, comprises two discs 33 and 34 held in spaced relation byspacer-tie rods 35, 36. Rods 35 are held in place by screws 37; rods 36are held in place by nuts 37' fitting on the reduced end of the rods.

Discs 33, 34 rest on flanged rollers 38 on which the assembled creelrotates. Rollers 38 are suitably journaled in the frame 39 of themachine. Attached to one disc of the creel, as shown also in FIG. 1, isa sprocket wheel 40 connected by a sprocket chain 41 to a drivingsprocket 42..

It will be noted in FIG. 7 that the spacer-tie rods 35, 36 are arrangedin pairs. These pairs of spacer tie rods are separated a sufiicientdistance to permit threading a strand 31 between them in such a mannerthat the strand 31 leaving the bobbin 43 passes over the outside tie rod65, then in between the two rods 35 and 36 and around a portion of theinside tie rod 36, thence to the reed generally referred to as 47. Thisarrangement of threading permits just enough tension to develop to windthe strands on the tube 10 and also to prevent the bobbin 43 from toofreely unwinding so that no additional tension or brake mechanism isrequired.

The function of the reed 47 is to guide the strands 31 to their properlocation on the web tube so that there is always the proper amount ofspace between the strands. This function becomes complicated whenseveral parallel strands are laid at one time from each of the severalreeds on the same creel.

Four reeds are shown on each creel although five or any other suitablenumber may be used. Since the reeds are of similar construction, it isonly necessary to describe one. he reed assembly 47 comprises a helicalstiff wire coil 48 surrounding a cylindrical rod or core 49 and formingtherewith a series of slots 56 between the convolutions of the coil. Oneend Stlof rod 49 is reduced and threaded into disc 34. The other end ofrod 49 has a square head 51 for engagement by a wrench to remove andreplace the reed assembly.

Spacing collar 52 of predetermined thickness holds the coil 48 therequired distance from disc 33. The other end of coil 48 is anchored ina hole 55 in adjustable collar 53 held in place by set screw 54.

The reed assembly is susceptible of a number of adjustments. Spacingcollar 52 may have dilferent thicknesses for the different reeds, tostagger the strands leaving the several reeds. The adjustable collar 53may be fixedly positioned at different points along rod 49 to vary theeffective length of the reed, as will be seen by comparing FIGURES 9 and10. And coil 48 (and collar 53) may be rotated about its axis toproperly position the slots 56.

The effects of'these adjustments are explained more in detail below.

The bobbins 43 carrying the strands 31 rotate on axles 6i) easilyremovable for replacement of fresh bobbins. A single bobbin, as shown,or a plurality of bobbins, may be mounted on the same axle 60. Aplurality of strands may be wound on a single bobbin, similar to aconventional warp beam in a conventional loom.

Referring to FIGS. 11 and 12, each axle is mounted on two stub shafts61, each mounted on its particular disc 33 and 34. The shaft 60 bridgesthe stubs 61. Shaft 60 is tubular and has each end half cut away to forma half cylinder trough 62. Troughs 62 rest on stubs 61. A collar 63surrounds the interfitted trough and stub, a set screw 64 engaging stub61 opposite trough 62 to hold shaft 60 centered with respect to stubs61.

It will be understood that the bobbin 43 has a small axial play on itsshaft 60 to permit axial shift of the collars 63 for removal of theshaft 60 and bobbin 43.

The work is propelled through the machine by puller rolls 17, one ofwhich is driven by a sprocket 65 mounted on roller shaft 66. Sprocket 65is driven by an electric motor 67 which drives suitable reduction gear68. Gear 68 has an output shaft 69 supporting a sprocket which driveschain 70 which drives puller roll sprocket 65.

Output shaft 69 also drives chain 74 which drives creel sprocket 75 (seealso FIG. 6). Sprocket 75 drives a bevel gear 76 which drives bevelgears 77, 78 in opposite directions. Bevel gear 77 drives gear 42 fordriving creel 18 in one direction, and bevel gear 78 drives gear 79 fordriving creel 19 in the opposite direction.

The buncher roll 23 rests on a pair of rolls 80, 81, the latter beingdriven by a suitable motor 82. The buncher mechanism, which is ofconventional construction, acts to rotate roll 23, to wind the finishedcomposite tape 10, 20 thereon.

The effect of reed adjustment will be briefly discussed. The machine issusceptible of adjustment due to requirements in practice, which may becaused by the different materials handled and the desired end product.Among the variables are speed of backing web, speed of rotation ofcreels, the number of strands per inch, the closeness of he Strands inany particular layer of strands, the number of layers it is desired eachcreel to lay, the width of a lay, etc.

For example, the faster the speed of the creels with respect to thespeed of the backing web, in general the shorter the effective length ofthe reeds. Suitable provision (not shown) may be made for varying therelative speed of puller rolls 1'7 and creels 1d, 19 to vary the pitchof the helical layers laid down by the creels on the preformed Web.

The spacing washers S2 of different width and the rotative adjustment ofthe coils 48 are used to avoid tracking, i.e. to avoid laying any strandparallel to and on top of a strand already laid. By thus staggering thestrands from the several reeds, the reeds lay down their strandsalongside of, and in proper relation to, strands laid down by otherreeds.

Due to the relatively great separation of the strands laid down by anyparticular reed, it is desired to have the several reeds lay theirparticular strands alongside of strands from other reeds, in order toget uniform spacing of strands in a single layer of strands.

The function of the transformer roll 22 will be briefly discussed. Theweb It 20 is circular in cross-section Where it leaves mandrel 15 atline X-X, and is straight in cross-section at the bite of the pullerrolls 17 at line Y-Y.

It is impossible, theoretically, at least, to transform the web fromtransverse circular form to straight form without stretching the web,although such stretching can be minimized by separating the points X-Xand YY a considerable distance. But it is uneconomical in a plant to usegreat distances. Furthermore, in the case where the web is part or allpaper, which has little stretch, the problem of transforming fromcircular to straight transverse sections is greater than with a morestretchable material.

In transforming from circular to straight transverse form, the paper webhas certain areas relatively taut and others relatively loose or full.Tests, have shown that this difficulty can be minimized by permittingthe web to gather or bunch at the slacker areas to permit the tauterareas to transform without being subject to stretching stress which maycause tearing.

The variable diameter contoured transformer roll 22 assists intransformation, by providing lower portions for the tauter areas andhigher portions for the fuller or longer areas. In the form shown, endareas 87 have the smallest diameter; areas 89 on either side of themidpoint have the largest diameter; and the midpoint area 88 has adiameter intermediate areas 87 and 89.

It is not necessary for the web to contact all points of the profile ofthe transformer roll to be effective but only suflicient contact isrequired to guide the tighter elements and to spread the websufficiently to permit smooth entry into the puller rolls 17.

The transformer roll 22 may be sectional, i.e. it may comprise a seriesof individual discs or rolls mounted to rotate freely on transformershaft 90, and independently of each other. The transformer roll 12'changing the web from straight to circular is constructed generallysimilar to roll 22.

Thus a method and machine has been provided which makes a reinforcedflexible web in an expeditious and inexpensive manner. The product inone specific form comprises the pre-formed tape to which the crossedstrands are adhesively bonded. The angle of the crossed strands withrespect to the longitudinal axis of the tape, as shown, is 45 degrees.This angle is obtained by making the longitudinal speed of the tapethrough the machine equal to the linear speed of the creels as measuredat the surface or" the tape. The angle of the strands may be varied bychanging the relative speeds of tape and creels.

The creel arrangement with reeds extending parallel to the axis ofrotation simplifies the laying down of the several lays of strands. Theadjustments of efiective reed length and of spacing between strand slotsor guides 56; and the provision for staggering the strands from theseveral reeds-all give the machine considerable versatility for handlingdifferent materials and for making different products. 7

While certain novel features of the invention have been disclosedherein, and are pointed out in the annexed claims, it will be understoodthat various omissions, substitutions and changes may be made by thoseskilled in the art without departing from the spirit of the invention.

What is claimed is:

1. In a machine for processing a web, means for passing said weblongitudinally through the machine, a tubular mandrel to support, and toimpart an annular cross section to, said web, a set of puller rolls, theline of bite of said puller rolls being transverse to the axis of saidmandrel and offset therefrom, said puller rolls imparting a straighttransverse configuration to said web, a transformer support having atransformer surface between said mandrel and puller rolls, saidtransformer support being so disposed with respect to said line of biteand to said mandrel axis that the web describes a substantial bendaround said transformer surface, said transformer surface having, in adirection transversely of the web, spaced relatively high points overwhich pass those portions of the web located between the center andmargins of the Web, a relatively low point over which passes the centerof the web, and relatively low points over which pass the margins of theweb.

2. In the machine of claim-1, said transformer support comprising a rollmade up of a series of circular disks independently rotatable, saiddisks having varying diameters.

References Cited in the file of this patent UNITED STATES PATENTS1,132,635 Subers Mar. 22, 1915 2,002,091 Jabouley May 21, 1935 2,021,095Ball Nov. 12, 1935 2,059,404 Skedgell Nov. 3, 1936 2,680,469 Ahier etal. June 8, 1954 2,696,243 Holland Dec. 7, 1954 FOREIGN PATENTS $167,150Australia Mar. 5, 1956

1. IN A MACHINE FOR PROCESSING A WEB, MEANS FOR PASSING SAID WEBLONGITUDINALLY THROUGH THE MACHINE, A TUBULAR MANDREL TO SUPPORT, AND TOIMPART AN ANNULAR CROSS SECTION TO, SAID WEB, A SET OF PULLER ROLLS, THELINE OF BITE OF SAID PULLER ROLLS BEING TRANSVERSE TO THE AXIS OF SAIDMANDREL AND OFFSET THEREFROM, SAID PULLER ROLLS IMPARTING A STRAIGHTTRANSVERSE CONFIGURATION TO SAID WEB, A TRANSFORMER SUPPORT HAVING ATRANSFORMER SURFACE BETWEEN SAID MANDREL AND PULLER ROLLS, SAIDTRANSFORMER SUPPORT BEING SO DISPOSD WITH RESPECT TOSID LINE OF BITE ANDTO SAID MANDREL AXIS THAT THE WEB DESCRIBES A SUBSTANTIAL BEND AROUNDSAID TRANSFORMER SURFACE, SAID TRANSFORMER SURFACE HAVING, IN ADIRECTION TRANSVERSELY OF THE WEB, SPACED RELATIVELY HIGH POINTS OVERWHICH PASS THOSE PORTIONS OF THE WEB LOCATED BETWEEN THE CENTER ANDMARGINS OF THE WEB, A RELATIVELY LOW POINT OVER WHICH PASSES THE CENTEROF THE WEB, AND RELATIVELY LOW POINTS OVER WHICH PASS THE MARGINS OF THEWEB.